Update on Alternative Occupant Volume Testing

Muhlanger

ASME 2011 Rail Transportation Division Fall Technical Conference

et al. 2011

Self Cite

The Office of Research and Development of the Federal Railroad Administration (FRA) and the Volpe Center have been conducting research into developing an alternative method of demonstrating the occupied volume integrity (OVI) of passenger rail equipment through a combination of testing and analysis. This research has been performed as a part of FRA Office of Research and Development's Railroad Safety Research and Development program, which provides technical data to support safety rulemaking and enforcement programs of the FRA Office of Railroad Safety. Previous works have been published on a series of full-scale, quasi-static tests intended to examine the load path through the occupant volume of conventional passenger cars retrofitted with crash energy management (CEM) systems. This paper reports on the most recent testing and analysis results.Before performing any tests of proposed alternative loading techniques, an elastic test of the passenger car under study was conducted. The elastic test served both to aid in validating the finite element (FE) model and to verify the suitability of the test car to further loading. In January, 2011, an 800,000 pound conventional buff strength test was performed on Budd Pioneer 244. This test featured arrays of vertical, lateral, and longitudinal displacement transducers to better distinguish between the deformation modes and rigid body motions of the passenger car. Pre-test car repairs included straightening a dent in one side sill and installing patches over cracks found in the side sills. Additionally, lateral restraints were added to the test frame due to concerns in previous tests associated with lateral shift in the frame. As a part of this testing program, a future test of a passenger car is planned to examine an alternative load path through the occupied volume. In the case of Pioneer 244, this load path places load on the floor and roof energy absorber support structures. Loading the occupant volume in this manner more closely simulates the loading the car would experience during a collision.FE analysis was used in conjunction with full-scale testing in this research effort. An FE model of the Pioneer car was constructed and the 800-kip test was analyzed. The 800-kip test results were then compared to the analysis results and the model was adjusted post-test so that satisfactory agreement was reached between the test and the model. In particular, the boundary conditions at the loading and reaction locations required careful attention to appropriately simulate the support conditions in the test. Because the 800-kip load was applied at the line of draft, this test results in significant bending as well as axial load on the car. To ensure that both the axial and bending behaviors are captured in the model, the key results that were compared between test and model are the longitudinal force-displacement behavior and the vertical deflections at various points along the car. The post-test model exhibited good agreement with the compared test results. The validate...

Section: Test Setupmentioning

confidence: 99%

Section: Test Setupmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Occupied Volume Integrity Testing: Elastic Test Results and Analyses

Muhlanger

ASME 2011 Rail Transportation Division Fall Technical Conference

et al. 2011

Self Cite

“…Additionally, this previous program demonstrated that the 1.2 million pound crippling load adopted by the ETF as one of its OVI criteria was a reasonable description of the minimum crippling load to be found in an 800-kip compliant railcar of conventional design. The progress of and results from the previous research program have been detailed in several recent publications [7], [8], [9].…”

Section: Introductionmentioning

confidence: 99%

Crippling Test of a Budd M-1 Passenger Railcar: Test and Analysis Results

2014 Joint Rail Conference

Tyrell

et al. 2014

Self Cite

The Federal Railroad Administration's (FRA) Office of Research and Development is conducting research into the occupied volume integrity (OVI) of passenger railcars. OVI refers to a passenger railcar's ability to preserve space for passengers and crew during accident loading conditions. The information developed in this research program will form the basis for establishing alternative OVI evaluation procedures. These alternative procedures, in turn, will allow a wider variety of passenger railcar designs to have their OVI evaluated, will provide guidance for applying modern engineering technologies, such as finite element analysis (FEA), and will continue to ensure a level of safety in evaluated vehicles equivalent to conventional evaluation.As part of this research program, two tests and corresponding FEA were conducted on a Budd M-1 passenger railcar that had been retrofitted with crash energy management (CEM) components on both ends. This testing and analysis program was sponsored by FRA and carried out by Transportation Technology Center, Inc. (TTCI), Arup, and the Volpe Center. An 800,000 pound load test was conducted on March 13, 2013 and was intended to elastically deform the car. The data generated during this test were, in turn, used to validate FE models of the M-1 car. The second test was performed on July 17, 2013. This test introduced loads into the occupant volume through its CEM attachment points until the ultimate, or crippling, load was reached. By loading the occupant volume through the CEM components, the test load path is similar to the load path that would be traveled by collision loads during activation of the CEM system. This paper presents the results of the crippling test, discusses the sequence of buckling that was observed to occur in the test, and compares the results of the test with the results from FEA of the test conditions. During the crippling test, the car exhibited a crippling load of 1.1 million pounds. This value is consistent with crippling loads reached by two Budd Pioneer cars that were previously tested in an FRA program. The buckling sequence of the members making up the M-1's occupant volume were particularly well-captured by strain gages during this most recent test. The load path through the occupant volume and the sequence of progressive buckling of structural members is discussed. Additionally, the presence of existing damage and previously-repaired areas and their likely effects on the crippling behavior of the car are discussed.

Crippling Test of a Budd Pioneer Passenger Car

2012 Joint Rail Conference

Tyrell

2012

This research program was sponsored by the Federal Railroad Administration (FRA) Office of Research and Development in support of the advancement of improved safety standards for passenger rail vehicles.FRA and the Volpe National Transportation Systems Center (Volpe Center) have conducted a research program to develop alternative methods for demonstrating occupied volume integrity (OVI) of passenger rail cars using a combination of testing and analysis. Previous publications have addressed the planning and progress of a series of tests intended to examine the collision load path through the occupant volume of passenger cars equipped with crash energy management (CEM) systems. This program has included an elastic 800-kip buff strength test, two quasi-static tests that loaded a passenger car to its ultimate (crippling) capacity, and corresponding finite element (FE) analyses of each test. This paper discusses the two crippling tests and the companion FE analyses.One alternative method for evaluating OVI moves the applied loads from the line of draft to the collision load path. This alternative methodology also permits a combination of testing and analysis to be used to demonstrate the car's OVI, in contrast to the conventional methodology (as prescribed in existing FRA regulations) which only permits testing. The alternative methodology was adopted as the recommendations developed by the Railroad Safety Advisory Committee's (RSAC) Engineering Task Force (ETF) in its "Technical Criteria and Procedures for Evaluating the Crashworthiness and Occupant Protection Performance of Alternatively-Designed Passenger Rail Equipment for Use in Tier I Service." The research program was undertaken to verify the efficacy of using a combination of elastic testing and plastic analysis to evaluate the OVI of a passenger car loaded along its collision load path as prescribed in the ETF report. Earlier in this research program an elastic test of a BuddPioneer car was used to validate an FE model of the car, per the ETF's procedures. This model was then modified to reflect the condition of the car in its crippling test configuration. The model was used to simulate the crippling behavior of the car, following the ETF's procedures. Two Pioneer cars were then tested to crippling to provide additional data to validate the FE model and the proposed alternative OVI evaluation.Because the test cars used in this research program were equipped with CEM systems, the alternative evaluation loads were placed at the locations where the energy-absorbing components attached to the occupant volume. During both crippling tests, loads were measured at each energy-absorber support location on the live and restrained ends of the car. Additional instrumentation used in the second crippling test included strain gages on the major longitudinal structural members, displacement transducers at each load location, and vertical, lateral, and longitudinal displacement transducers on the underframe of the car. The results of the FE analysis compare favorabl...